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Visual Acuity One of the most obvious prerequisites is that the visual examiner should have sufficient visual acuity to perform an adequate inspection. Consideration should be given to near and far vision with natural or corrected vision.
Certification Programme To provide assurance that visual inspectors are qualified (that is, sufficient prerequisites are obtained and maintained), it may be desirable to have visual inspection personnel formally certified. Certification is a testimony of qualification.
Certification Programme The American Welding Society offers Certified Welding Inspector (CWI) and Certified Associate Welding Inspector (CAWI) programme. Other programme such as TWI / CSWIP also offers such programme.
Safety Visual inspectors should receive sufficient indoctrination on welding safety practices. There are many potential safety hazards present (electricity, gases, fumes, ultraviolet light, heat, etc.).
Discovery and repair of any defects at that time results in substantial cost reduction. It has been shown that a conscientious programme of visual inspection occurring before, during, and after welding can result in discovery of the majority of all defects which would have been detected later using more expensive test methods.
The effectiveness of visual inspection is improved when a system is instituted which provides for coverage at all phases of the welding process (before, during, and after welding). The sooner the examination process is introduced into the system, the better the coverage.
Joint Configuration
All of these factors could have a direct bearing on the resultant weld quality. If the fit-up is poor, then the weld will most likely be of substandard quality as well. Extra care taken during the joint assembly can greatly improve welding effectiveness. Sometimes, examination of the joint prior to welding will reveal irregularities within code limitations, but these becomes areas of concern and can be watched carefully during later stage.
During Welding. During welding, there are a number of items which require control so that the resulting weld will be satisfactory. Visual examination is the primary method for controlling this aspect of the fabrication.
Between Layer Examination Many of these items may be addressed in the applicable welding procedure. In that case, visual inspection performed during the welding is basically a check to determine id there is compliance with the requirements of the welding procedure.
Weld Discontinuities
Final Dimensional Examination Another measurement that affects the performance of a weldment is its dimensional accuracy. If a welded part will not fit an assembly, it may be useless, even though the weld is of adequate quality.
Welding heat will distort the base metal, and can alter overall component dimensions. Therefore, dimensional examination after welding may be required to determine the weldmentss fitness for its intended use.
Four basic weld joints are considered in this presentation: Butt T Corner Lap
Discontinuities & Defects Other conditions, such as high restraint and limited access to portions of a weld joint, may lead to a higher than normal incidence of weld and base metal discontinuities.
Incomplete fusion is termed as fusion which does not occur over the entire base metal surfaces intended for welding and between all adjoining weld beads. Incomplete fusion can result from insufficient heat input or the improper manipulation of the welding electrode. While it is a discontinuity more commonly associated with weld technique, it could also be caused by the presence of contaminants on the surface being welded.
Laminar Tearing
Throat Cracks Throat cracks are longitudinal cracks in the weld face in the direction of the weld axis. They are generally, but not always hot cracks.
Root Cracks. Root cracks are longitudinal cracks in the weld root. They are generally hot cracks.
Crater Cracks Crater cracks occur in the weld crater and are formed by improper termination of welding arc. A non standard term for crater cracks is star cracks though they may have other shapes. Crater cracks are shallow hot cracks usually forming a multi-pointed star-like cluster.
Slag Inclusion
Weld Profile
Videoscope